Welding tool and method of using a welding tool

ABSTRACT

A welding tool includes a tool support and a welding torch coupled to the tool support. The welding tool is configured to rotate relative to the tool support about a welding axis. A locating device is coupled to the tool support and is movable between a retracted position and an extended position. In the extended position, the locating device extends toward the welding axis. The locating device includes a recess at an end of the locating device. The recess is configured such that, when a predetermined object to be welded (such as an anchor rod) is positioned at least partially within the recess of the locating device in the extended position, the welding axis passes through the object to be welded.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.16/372,311, entitled “Welding Tool and Method of Using a Welding Tool”and filed on Apr. 1, 2019, the entirety of which is hereby incorporatedby reference.

FIELD OF THE DISCLOSURE

The present disclosure relates to a welding tool and to a method ofusing a welding tool.

BACKGROUND TO THE DISCLOSURE

Welding torches are used to weld together metal objects. When many weldsare required, for example for large construction projects, it can belaborious and time consuming for a human to repetitively produce manywelds of a consistently high quality. In addition, requiring a human toproduce a large number of such welds may lead to mobility, health,and/or ergonomics issues. Although the ability to produce multiple weldsof a consistently high quality has been automated to some extent, suchautomated devices are typically not easily portable, and the objects tobe welded generally have to be brought to the welding device forwelding.

SUMMARY OF THE DISCLOSURE

According to a first aspect of the disclosure, there is provided awelding tool comprising: a support structure; a welding torch coupled tothe support structure and configured to rotate relative to the supportstructure about a welding axis; and a locating device coupled to thesupport structure and movable between a retracted position and anextended position in which the locating device extends toward thewelding axis, wherein the locating device comprises a recess at an endthereof and is configured such that, when an object to be welded ispositioned at least partially within the recess of the locating devicein the extended position, the welding axis passes through the object tobe welded.

Thus, with the welding tool described above, multiple welds surroundinganchor rods (or other suitable objects to be welded) may be rapidly andaccurately produced. The welding tool may be operated by a labourer (aqualified welder is ideally not required).

The welding torch may be rotatably coupled to the support structure soas to rotate about the welding axis.

The recess may be sized and/or shaped such that, when the object to bewelded is positioned at least partially within the recess of thelocating device in the extended position, the welding axis passesthrough the object to be welded.

The recess may comprise a triangular shape.

The locating device may be configured to rotate between the retractedposition and the extended position. The locating device may be furtherconfigured to translate toward and away from the welding axis.

The support structure may comprise one or more magnets for securing thewelding tool to a work surface. The magnets may be provided in a base ofthe support structure.

An angle of the welding torch relative to the welding axis may beadjustable.

The support structure may comprise a base with a central aperture formedtherein. In the extended position, the locating device may extend intothe central aperture.

The locating device may comprise a first portion coupled to the supportstructure and a second portion extending at an angle (e.g. anon-horizontal angle) to the first portion, and the recess may be formedwithin the second portion. When the locating device is in the extendedposition, the second portion may extend through the central aperture.

The second portion may comprise a first member extending at an angle(e.g. a non-horizontal angle) to the first portion and a second memberextending at an angle (e.g. a non-horizontal angle) to the first member.The recess may be formed within the second member. When the locatingdevice is in the extended position, the second member may extendperpendicular to the welding axis.

The object to be welded may comprise an anchor rod. In some embodiments,the object to be welded may comprise any other suitable object, such asa circular plate.

The welding tool may further comprise a controller configured toimplement a method comprising: activating the welding torch; rotatingthe welding tool about the welding axis; and deactivating the weldingtorch. For example, the controller may be communicatively coupled to thewelding torch so as to cause the welding torch to activate anddeactivate. The controller may furthermore control one or more motors orsimilar devices for causing the welding tool to rotate about the weldingaxis. For example, the motors may cause a rotatable element of thesupport structure, to which the welding tool is coupled, to rotaterelative to the support structure.

The welding tool may be portable by a user. For example, it may bepossible to relocate the welding tool manually, without the need for ahoist or lift.

According to further aspect of the disclosure, there is provided awelding tool comprising: a support structure; a welding torch coupled tothe support structure and configured to rotate relative to the supportstructure about a welding axis; and a locating device coupled to thesupport structure and rotatable between a retracted position and anextended position in which the locating device extends toward thewelding axis, wherein the locating device is configured such that, whenan object to be welded is positioned in contact with an end of thelocating device in the extended position, the welding axis passesthrough the object to be welded.

The welding tool may comprise any of the features described above inconnection with the first aspect of the disclosure.

According to further aspect of the disclosure, there is provided asystem comprising: any of the above-described welding tools; and acontroller configured to implement a method comprising: activating thewelding torch; rotating the welding torch about the welding axis; anddeactivating the welding torch. The method may further comprise movingthe locating device from the extended position to the retracted positionprior to activating the welding torch. Moving the locating device fromthe extended position to the retracted position may comprise translatingthe locating device away from the welding axis and rotating the locatingdevice relative to the support structure.

The method may further comprise moving the locating device from theretracted position to the extended position after deactivating thewelding torch. For example, the controller may control one or moremotors or similar devices for causing the locating device to movebetween the retracted position to the extended position.

The method may further comprise, prior to moving the locating devicefrom the extended position to the retracted position, activating the oneor more magnets comprised in the support structure.

The method may further comprise, prior to activating the welding tool,rotating the welding tool about the welding axis.

The controller may comprise: circuitry; or a processor communicativewith memory having stored thereon computer program code configured whenexecuted by the processor to cause the processor to implement themethod.

The system may comprise any of the features described above inconnection with the first aspect of the disclosure.

In a further aspect of the disclosure, there is provided a method ofwelding, comprising: providing any of the above-described welding tools;when the locating device is in the extended position, positioning theobject to be welded in contact with the end of the locating device suchthat the welding axis passes through the object to be welded; moving thelocating device to the retracted position; activating the welding torch;and rotating the welding torch about the welding axis so as to weld theobject to be welded.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the disclosure will now be described in conjunction withthe accompanying drawings of which:

FIG. 1 is a schematic diagram of a welding tool according to embodimentsof the disclosure;

FIG. 2 is a view of an underside of the welding tool of FIG. 1 ;

FIG. 3 shows a centering leg in an extended position, according toembodiments of the disclosure;

FIG. 4 shows the centering leg of FIG. 3 in a retracted position;

FIG. 5 shows a welding tool according to embodiments of the disclosure;

FIG. 6 is a flow diagram of a method of using a welding tool, accordingto embodiments of the disclosure;

FIG. 7 shows schematic diagrams of different welds;

FIG. 8 shows an 8 mm fillet weld;

FIG. 9 shows a penetration profile of a weld; and

FIG. 10 shows a result of a pull test.

DETAILED DESCRIPTION OF EMBODIMENTS

The present disclosure seeks to provide an improved welding tool andmethod of using such a welding tool. While various embodiments of thedisclosure are described below, the disclosure is not limited to theseembodiments, and variations of these embodiments may well fall withinthe scope of the disclosure which is to be limited only by the appendedclaims.

The word “a” or “an” when used in conjunction with the term “comprising”or “including” in the claims and/or the specification may mean “one”,but it is also consistent with the meaning of “one or more”, “at leastone”, and “one or more than one” unless the content clearly dictatesotherwise. Similarly, the word “another” may mean at least a second ormore unless the content clearly dictates otherwise.

The terms “coupled”, “coupling” or “connected” as used herein can haveseveral different meanings depending on the context in which these termsare used. For example, the terms coupled, coupling, or connected canhave a mechanical or electrical connotation. For example, as usedherein, the terms coupled, coupling, or connected can indicate that twoelements or devices are directly connected to one another or connectedto one another through one or more intermediate elements or devices viaan electrical element, electrical signal or a mechanical elementdepending on the particular context. The term “and/or” herein when usedin association with a list of items means any one or more of the itemscomprising that list.

As used herein, a reference to “about” or “approximately” a number or tobeing “substantially” equal to a number means being within +/−10% ofthat number.

Generally, according to embodiments of the disclosure, there isdescribed an automated welding tool. The welding tool includes a weldingtorch configured to rotate about a welding axis, and a locating device(which may also be referred to as a centering leg) used to position anobject to be welded (which according to embodiments may be an anchorrod) on the welding axis. The welding tool may incorporate multiplebracing pillars on rubber feet to provide a stable structure that hassufficient weight to remain in place throughout rotation of the weldingtorch. At one end thereof, the centering leg includes a tailored recessor notch for properly aligning the anchor rod on the welding axis,thereby ensuring that the welding torch has a consistent line into thejoint.

The welding torch may be provided at an adjustable angle and a pre-setelevation relative to the base of the support structure, and may beconfigured to rotate around the centre of the structure. The weld may beperformed in one direction of rotation and then in the other, thusensuring that no kinks arise in the welding cable that would result inwire feeding issues. After placement of the anchor rod into the recessof the centering leg, but prior to the welding sequence, the centeringleg automatically retracts into an upright position to allow freerotation of the welding torch.

The figures will now be described in more detail. Turning to FIG. 1 ,and according to embodiments of the disclosure, welding tool 10comprises a tool support structure 12 including a base 14, an uppersupport 16, and multiple bracing pillars 18 extending from base 14 toupper support 16. A circular handle 20 extends upwardly from uppersupport 16. Welding tool 10 further includes a welding torch 22rotatably coupled to upper support 16 by means of a rotator 24 and atorch support 26. Rotator 24 and torch support 26 are shown in moredetail in FIG. 2 which shows an underside of welding tool 10. Rotator 24is configured to allow welding torch 22 to rotate through 360 degreesabout a welding axis W passing through the centre of welding tool 10.Welding torch 22 comprises a torch body 28 joined to a welding cable 30extending through a central aperture 32 formed within upper support 16.As can be seen in FIG. 2 , the underside of bracing pillars 18 includerubber feet 34, and magnets 36 are provided within base 14.

Welding tool 10 further includes a locating device, or centering leg 38,shown in more detail in FIGS. 3 and 4 . Centering leg 38 is rotatablycoupled to tool support structure 12. In particular, welding tool 10includes an actuable arm 40 configured to move centering leg 38 betweenan extended position and an upright, retracted position. The extendedposition of centering leg 38 can be seen in more detail in FIG. 3 , andthe retracted positon of centering leg 38 can be seen in more detail inFIG. 4 . Centering leg 38 includes a first portion 42 rotatably attachedto base 14, and a second portion 44 rotatable relative to first portion42. Second portion 44 includes an angled extension 46 extending awayfrom first portion 42 at a downward angle thereto, and an end portion 48extending away from angled extension 46 at an angle thereto. End portion48 is substantially parallel to first portion 42. In the extendedposition, centering leg 38 extends through a central aperture 50 formedwithin base 14.

End portion 48 of centering leg 38 includes a recess or notch 52 formedtherein. Notch 52 comprises generally a triangular shape at the end ofcentering leg 38, although the skilled person will recognize that thedisclosure extends to recesses having other suitable shapes. Notch 52 issized such that, when an anchor rod 54 is positioned within notch 52 andin contact with the sides of notch 52, welding axis W passes through thecentre of anchor rod 54.

Turning to FIG. 5 which shows welding tool 10 according to embodimentsof the disclosure, welding tool 10 includes a controller 56 forcontrolling operation of welding tool 10. In particular, controller 56includes circuitry configured to enable welding tool 10 to performvarious actions. For example, controller 56 may activate magnets 36 inorder for welding tool 10 to be secured to a metallic work surface 58(FIGS. 3 and 4 ). Controller 56 may additionally control the extensionand retraction of centering leg 38, as well as the rotation of rotator24 relative to upper support 16. Furthermore, controller 56 may controlactivation and deactivation of welding torch 22. In some embodiments,instead of or in addition to circuitry, controller 56 may comprise aprocessor communicative with memory having stored thereon computerprogram code configured, when executed by the processor, to cause theprocessor to implement one or more of the above functions. Furtherstill, in some embodiments controller 56 may be provided independentlyof welding tool 10, and controller 56 may be configured for example tocontrol welding tool 10 remotely.

Turning to FIG. 6 , according to embodiments of the disclosure there isshown a method 60 of performing welding, using welding tool 10.Centering leg 38 is initially in the extended position. At block 61,welding tool 10 is positioned over the anchor rod 54 to be welded. Inparticular, anchor rod 54 is located within notch 52 of centering leg 38and is positioned in contact with the sides of notch 52. At block 62, auser uses controller 56 to activate magnets 36. Once magnets 36 areactivated, at block 63, the user may then push downwardly on weldingtool 10, using handle 20. Through the downward force applied to weldingtool 10, rubber feet 34 compress and magnets 36 approach metal worksurface 58 until welding tool 10 is securely engaged to work surface 58.Controller 56 is then used to initiate a welding sequence, as follows.In particular, at block 64, controller actuates arm 40 to rotatecentering leg 38 into the retracted position. At block 65, controller 56activates welding torch 22. At block 66, controller 56 rotates weldingtorch 22 to form the joint between anchor rod 54 and work surface 58. Insome embodiments, welding torch 22 is rotated through an angle ofgreater than 360 degrees (in some embodiments, 368 degrees). Thisenables the start of the weld to be filled. At block 67, controller 56deactivates welding torch 22. Rotator 24 may then rotate welding torch22 back to its original position, to ensure that no kinks develop inwelding cable 30. At block 68, controller 56 actuates arm 40 to rotatecentering leg 38 into the extended position, for subsequent welding.

In some embodiments, a user may use controller 56 to rotate weldingtorch 22 a predetermined amount, for example prior to welding. Thisallows a user to determine the point at which welding torch 22 beginswelding.

Experimental Results

Three different welds were initially considered, as set out below and asshown in FIG. 7 .

-   -   1. ⅜″ [10 mm] fillet weld (Type-A);    -   2. 5/16″ [8 mm] fillet weld (Type-B); and    -   3. ¼″ [6 mm] fillet weld (Type-C).

Three separate specimens were originally considered for three test types(a total of nine tests) using a ⅜″ all-around fillet weld (Type A), a5/16″ fillet weld (Type B) and a ¼″ fillet weld (Type C) for the anchorrod to plate connection. A heavy, 2″ plate was used to simulate theconcrete-filled core backing the shell plate.

Testing was run to failure, with all Type A and Type B specimensexhibiting yielding to fracture failure, while two of three Type Cconnections exhibited the same failure behavior. One Type C (¼″ weld)had the weld fracture and rod pull through the plate. This was a resultof both minimum weld material and heat input. In summary, the 6 mm (¼″)fillet weld was of adequate size to satisfy the structural requirementsof the anchor rod fillet weld, but given the travel speed during weldingnecessary to generate the smaller fillet weld size, it is unrealistic to

TABLE 1 Welding parameters for test samples and process/consumableinformation. Sample Wire Feed Speed Voltage Travel Wire Dia. # m/min[ipm] V Setting Process Wire mm 1 7.62 [300] 32 25 MCAW E491C-6MJ-H4 1.6E70C-6M-H4 2 7.62 [300] 32 25 MCAW E491C-6MJ-H4 1.6 E70C-6M-H4 3 7.62[300] 32 25 MCAW E491C-6MJ-H4 1.6 E70C-6M-H4 4 7.62 [300] 32 25 MCAWE491C-6MJ-H4 1.6 E70C-6M-H4 5 8.89 [350] 28 18/19 FCAW E491T-9MJ-H8 1.6E71T-9M-JH8 13 8.89 [350] 28 18/19 FCAW E491T-9MJ-H8 1.6 E71T-9M-JH8 158.89 [350] 28 18/19 FCAW E491T-9MJ-H8 1.6 E71T-9M-JH8 18 8.89 [350] 2818/19 FCAW E491T-9MJ-H8 1.6 E71T-9M-JH8produce consistent penetration profiles at these speeds.

The 8 mm ( 5/16″) fillet option provides an improved compromise betweenwelding efficiency and a consistent weld that meets the structuralrequirements. A manually welded 8 mm fillet weld underwent mechanicaltesting, showing that the failure upon tensile testing occurs within theanchor rod, exhibiting a traditional necking to failure mechanism. Anexample of the 8 mm fillet weld produced by the welding tool can be seenin FIG. 8 .

Eight rod specimens welded using the automated welding tool werecompleted, four using metal-cored arc welding (MCAW) and another fourusing flux-cored arc welding (FCAW). The welding parameters andinformation regarding the consumables and welding processes for the testsamples are shown in Table 1.

FIG. 8 shows a representative example of a weld produced using theautomated welding tool. The use of the 1.6 mm electrode allowed forincreased welding efficiency and increased the current level as comparedto the 1.3 mm wire which in turn led to a deeper penetration profile.The deeper penetration profile can be seen in FIG. 9 . It was observedthat for welds with insufficient penetration profiles, the failure modeof the anchor rod specimens still occurred within the rod, but occurredat the top of the anchor rod, in close proximity to the weld.

In four pull tests on the rod setup with both metal-cored arc weldingMCAW and flux-cored arc welding FCAW, in all cases the failure occurredin the rod and the weld remained unaffected. These results clearly showthat the 8 mm fillet weld generated with the automated welding tool isrobust and consistent. An example of the pull test results is shown inFIG. 10 .

Based on the results of tension testing and the consistency of the weldsproduced, the automated welding tool has been shown to provide asatisfactory weldment, particularly with the MCAW process. The use ofthe 1.6 mm consumable allowed for a significant (˜50%) reduction in thewelding time for one anchor rod. The deep penetration profile andconsistent outer weld profile indicate that this process can effectivelyprovide reliable results.

While the disclosure has been described in connection with specificembodiments, it is to be understood that the disclosure is not limitedto these embodiments, and that alterations, modifications, andvariations of these embodiments may be carried out by the skilled personwithout departing from the scope of the disclosure. It is furthermorecontemplated that any part of any aspect or embodiment discussed in thisspecification can be implemented or combined with any part of any otheraspect or embodiment discussed in this specification.

The invention claimed is:
 1. A welding tool comprising: a supportstructure; a welding torch coupled to the support structure andconfigured to rotate relative to the support structure about a weldingaxis, wherein the welding axis is defined by rotation of the weldingtorch relative to the support structure; and a locating device coupledto the support structure and movable between a retracted position and anextended position, wherein in the extended position an end of thelocating device is closer to the welding axis than in the retractedposition such that a perpendicular distance between the end of thelocating device and the welding axis when in the retracted position isgreater than the perpendicular distance between the end of the locatingdevice and the welding axis when in the extended position, wherein theperpendicular distance is a distance along a line extending from the endof the locating device and intersecting the welding axis at a rightangle, and wherein the locating device comprises a recess at the end andis configured such that, when an object to be welded is positioned atleast partially within the recess of the locating device in the extendedposition, the welding axis passes through the object to be welded. 2.The welding tool of claim 1, wherein the recess comprises a triangularshape.
 3. The welding tool of claim 1, wherein the locating device isconfigured to rotate between the retracted position and the extendedposition.
 4. The welding tool of claim 1, wherein the support structurecomprises one or more magnets for securing the welding tool to a worksurface.
 5. The welding tool of claim 1, wherein an angle of the weldingtorch relative to the welding axis is adjustable.
 6. The welding tool ofclaim 1, wherein the support structure comprises a base with a centralaperture formed therein.
 7. The welding tool of claim 6, wherein, in theextended position, the locating device extends into the centralaperture.
 8. The welding tool of claim 1, wherein the locating devicecomprises a first portion coupled to the support structure and a secondportion extending at an angle to the first portion, and wherein therecess is formed within the second portion.
 9. The welding tool of claim8, wherein, when the locating device is in the extended position, thesecond portion extends through the central aperture.
 10. The weldingtool of claim 8, wherein the second portion comprises a first memberextending at an angle to the first portion and a second member extendingat an angle to the first member, wherein the recess is formed within thesecond member, and wherein, when the locating device is in the extendedposition, the second member extends perpendicular to the welding axis.11. The welding tool of claim 1, wherein the object to be weldedcomprises an anchor rod.
 12. The welding tool of claim 1, furthercomprising a controller configured to implement a method comprising:activating the welding torch; rotating the welding torch about thewelding axis; and deactivating the welding torch.
 13. The welding toolof claim 12, wherein the method further comprises moving the locatingdevice from the extended position to the retracted position prior toactivating the welding torch.
 14. The welding tool of claim 13, whereinthe support structure comprises one or more magnets for securing thewelding tool to a work surface, and wherein the method furthercomprises, prior to moving the locating device from the extendedposition to the retracted position, activating the one or more magnets.15. The welding tool of claim 12, wherein the method further comprisesmoving the locating device from the retracted position to the extendedposition after deactivating the welding torch.
 16. The welding tool ofclaim 12, wherein the method further comprises, prior to activating thewelding torch, rotating the welding torch about the welding axis. 17.The welding tool of claim 12, wherein the controller comprises:circuitry; or a processor communicative with memory having storedthereon computer program code configured when executed by the processorto cause the processor to implement the method.
 18. The welding tool ofclaim 1, wherein the welding tool is portable by a user.